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EP0946458A1 - Procede de fabrication d'un materiau composite ceramique - Google Patents

Procede de fabrication d'un materiau composite ceramique

Info

Publication number
EP0946458A1
EP0946458A1 EP97936901A EP97936901A EP0946458A1 EP 0946458 A1 EP0946458 A1 EP 0946458A1 EP 97936901 A EP97936901 A EP 97936901A EP 97936901 A EP97936901 A EP 97936901A EP 0946458 A1 EP0946458 A1 EP 0946458A1
Authority
EP
European Patent Office
Prior art keywords
composite material
reinforcing
matrix
immersed
interface
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP97936901A
Other languages
German (de)
English (en)
Other versions
EP0946458B1 (fr
Inventor
Robert Lundberg
Magnus Holmquist
Anthony Gordon Razzell
Ludovic Molliex
Olivier Sudre
Michel Parlier
Fabrice Rossignol
Julien Parmentier
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Office National dEtudes et de Recherches Aerospatiales ONERA
Safran Aircraft Engines SAS
Rolls Royce PLC
GKN Aerospace Sweden AB
Original Assignee
Office National dEtudes et de Recherches Aerospatiales ONERA
Societe Nationale dEtude et de Construction de Moteurs dAviation SNECMA
SNECMA SAS
Rolls Royce PLC
Volvo Aero AB
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Office National dEtudes et de Recherches Aerospatiales ONERA, Societe Nationale dEtude et de Construction de Moteurs dAviation SNECMA, SNECMA SAS, Rolls Royce PLC, Volvo Aero AB filed Critical Office National dEtudes et de Recherches Aerospatiales ONERA
Publication of EP0946458A1 publication Critical patent/EP0946458A1/fr
Application granted granted Critical
Publication of EP0946458B1 publication Critical patent/EP0946458B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/628—Coating the powders or the macroscopic reinforcing agents
    • C04B35/62844—Coating fibres
    • C04B35/62857—Coating fibres with non-oxide ceramics
    • C04B35/62873—Carbon
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
    • C04B35/111—Fine ceramics
    • C04B35/117—Composites
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/628—Coating the powders or the macroscopic reinforcing agents
    • C04B35/62844—Coating fibres
    • C04B35/62847—Coating fibres with oxide ceramics
    • C04B35/62855—Refractory metal oxides
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/628—Coating the powders or the macroscopic reinforcing agents
    • C04B35/62892—Coating the powders or the macroscopic reinforcing agents with a coating layer consisting of particles
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/628—Coating the powders or the macroscopic reinforcing agents
    • C04B35/62894—Coating the powders or the macroscopic reinforcing agents with more than one coating layer
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/628—Coating the powders or the macroscopic reinforcing agents
    • C04B35/62897—Coatings characterised by their thickness
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/64—Burning or sintering processes
    • C04B35/645—Pressure sintering
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5216—Inorganic
    • C04B2235/522—Oxidic
    • C04B2235/5224—Alumina or aluminates

Definitions

  • the present invention refers to a method of manufacturing a ceramic composite material comprising matrix and reinforcing materials and an intermediate weak interface material, said composite material being particularly intended for use at temperatures above 1400°C and in an oxidizing environment, the matrix and reinforcing materials consisting of the same or dif- ferent ceramic oxides having a melting point above 1600°C, and the interface material providing in combination with said materials a stress field liable to micro-cracking.
  • the main object of the present invention is to suggest a method by which an even weaker interface is obtained.
  • the reinforcing fibre material is immersed into a powder slurry containing carbon and Zr0 2 so as to be coated thereby and then dried, after which the composite material is subjected to green forming and densification steps as known per se, and finally a heat-treatment in air leaving a porous structure of the interface material.
  • the reinforcing fibre material is immersed into and coated with a first powder slurry contain- ing Zr0 2 and then- dried and immersed into and .
  • the coating formed on fibres of which the reinforcing material consist and which are immersed in the slurry has proved to be adherent and strong enough to survive green forming and densification processes.
  • the C is removed by heat treatment in air, leaving a gap or porosity in the oxide interface.
  • the volume fraction of C can be varied to achieve the desired interface strength.
  • the interface made by this invention is stable at high temperatures for long times because the pores have got the right size, i.a. are large enough .
  • the re- inforcement is first immersed in a C powder slurry, dried and then immersed in an oxide (Zr0 2 ) powder slurry, forming a double . or sequential coating. Again, this coating is strong and adherent enough to survive green forming and densification. After densification the C is removed by heat treatment leaving a gap between the reinforcing material and the oxide interface. Surface roughness of the reinforcing and matrix materials is sufficient to give load transfer between reinforcing material and matrix materia-1.
  • the absence of bonding between the oxide interface and the reinforcing material will ensure effective crack deflection.
  • the degree of load transfer and frictional sliding resistance between reinforcing material and matrix con- trolling the fibre pullout behaviour can be varied by varying the thickness of the fugitive C layer.
  • Example 1 Single crystal fibres of Al 2 0 3 (from Saphikon Inc., USA) were covered with a thin layer of C/Zr0 2 mixture. This was made by immersing the fibres in a slurry of C/Zr0 2 -powder in water. The volume proportions of C to Zr0 2 was 1/1. After drying the coated fibres were stacked to a fibre preform in a plaster mould. A Al 2 0 3 powder slurry was poured thereon and a pressure gradient was applied to give good infiltration of the fibre preform.
  • Example 1 was repeated however using Hf0 2 instead of Zr0 2 .
  • Example 3 Single crystal fibres of Al 2 0 3 (from Saphikon Inc., USA) were covered with at thin double layer of C and Zr0 2 . This was made by first immersing the fibres in a slurry of Zr0 2 -powder in water and then immersing the fibres in a slurry of C-powder in water. After drying the coated fibres were stacked to a fibre preform in a plaster mould. An Al 2 0 3 powder slurry was poured thereon and a pressure gradient was applied to give good infiltration of the fibre preform.
  • the green bodies were sintered by hot- pressing at 1400°C, at 10 MPa for 70 minutes.
  • the C was burnt out by heat treatment at 1250°C for 10 hours leaving a gap of about 1 ⁇ m between the zirconia layer and the Al 2 0 3 matrix.
  • the Zr0 2 layer was about 3 ⁇ m of thickness and not bonded to the matrix.
  • the gap between fibre and Zr0 2 layer provided crack deflection and fibre pullout which was proved by bending tests.
  • Example 4 Example 3 was repeated however using Hf0 2 instead of Zr0 2 .
  • Example 5 - Example 3 was repeated, however with the steps in slightly reversed order, i.e. by first immersing the fibres in a slurry of C-powder in water and then in a slurry of Zr0 2 - powder, with similar advantageous result.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Composite Materials (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Porous Artificial Stone Or Porous Ceramic Products (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Ceramic Products (AREA)

Abstract

L'invention porte sur un procédé de fabrication d'un matériau composite céramique comprenant une matrice, des matériaux de renfort, et un matériau interface faible. Ledit matériau composite est particulièrement adapté aux températures supérieures à 1400 °C et aux atmosphères oxydantes. La matrice et les matériaux de renfort sont en oxydes céramiques identiques ou différents, d'un point de fusion supérieur à 1600 °C, et le matériau interface fournit, en association avec les autres matériaux, un champ de contraintes susceptible de microcraquelures. Selon l'invention, le matériau fibreux de renfort est plongé dans une boue pulvérulente contenant du carbone (C) et du ZrO2 dont il s'imprègne, puis séché. Il est ensuite transformé en pâte verte puis soumis à des étapes de densification connues per se, puis finalement à un traitement thermique laissant une structure poreuse sur le matériau interface.
EP97936901A 1997-08-11 1997-08-11 Procede de fabrication d'un materiau composite ceramique Expired - Lifetime EP0946458B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/SE1997/001340 WO1999007653A1 (fr) 1997-08-11 1997-08-11 Procede de fabrication d'un materiau composite ceramique

Publications (2)

Publication Number Publication Date
EP0946458A1 true EP0946458A1 (fr) 1999-10-06
EP0946458B1 EP0946458B1 (fr) 2001-11-28

Family

ID=20406529

Family Applications (1)

Application Number Title Priority Date Filing Date
EP97936901A Expired - Lifetime EP0946458B1 (fr) 1997-08-11 1997-08-11 Procede de fabrication d'un materiau composite ceramique

Country Status (7)

Country Link
US (1) US6251317B1 (fr)
EP (1) EP0946458B1 (fr)
JP (1) JP2001502290A (fr)
CA (1) CA2268019C (fr)
DE (1) DE69708682T2 (fr)
ES (1) ES2164364T3 (fr)
WO (1) WO1999007653A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7105224B2 (en) 2001-11-23 2006-09-12 Fraunhofer-Gesellschaft Zur Foerderung Der Angewandten Forschung E.V. Oxide ceramic fiber composite materials and use thereof

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2778655B1 (fr) * 1998-05-15 2000-08-11 Aerospatiale Procede d'elaboration d'un materiau d'interphase, materiau obtenu, procede de traitement d'une fibre ceramique de renfort avec ce materiau et materiau thermostructural incluant de telles fibres
EP2181974B1 (fr) * 2008-10-31 2012-03-21 AVIO S.p.A. Procédé pour la production de composants fabriqués à partir d'un matériau composite à matrice céramique
US8309197B2 (en) * 2008-12-17 2012-11-13 Teledyne Scientific & Imaging, Llc Integral abradable seals
GB201006625D0 (en) 2010-04-21 2010-06-02 Rolls Royce Plc A method of manufacturing a ceramic matrix composite article
FR3041890B1 (fr) * 2015-10-05 2017-11-24 Snecma Procede de fabrication d'une piece en materiau composite par injection d'une barbotine chargee dans un moule poreux
JP7187369B2 (ja) 2019-03-25 2022-12-12 三菱重工航空エンジン株式会社 セラミックス基複合材料の製造方法
US11787746B1 (en) * 2021-02-10 2023-10-17 Hrl Laboratories, Llc Compressible coating reinforcements for ceramic matrix composites, and methods of making the same
CN118812268B (zh) * 2024-07-24 2025-10-28 哈尔滨工业大学 一种C/ZrO2复合涂层改性纤维莫来石先驱体的制备方法

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4732877A (en) 1985-09-30 1988-03-22 Allied-Signal Inc. Alumina composite reinforced by zirconia-clad alumina fibers
US4885199A (en) * 1986-08-06 1989-12-05 Norton Company Fiber-reinforced silicon nitride composite ceramics
US5290491A (en) 1990-04-02 1994-03-01 Societe Europeenne De Propulsion Process for the manufacture of a thermostructural composite material having a carbon interphase between its reinforcement fibers and its matrix
FR2685693B1 (fr) * 1991-12-30 1994-06-03 Europ Propulsion Procede de realisation d'une protection contre l'oxydation de produits en materiau composite, et produits ainsi proteges.

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO9907653A1 *

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7105224B2 (en) 2001-11-23 2006-09-12 Fraunhofer-Gesellschaft Zur Foerderung Der Angewandten Forschung E.V. Oxide ceramic fiber composite materials and use thereof

Also Published As

Publication number Publication date
CA2268019A1 (fr) 1999-02-18
US6251317B1 (en) 2001-06-26
ES2164364T3 (es) 2002-02-16
DE69708682T2 (de) 2002-08-08
EP0946458B1 (fr) 2001-11-28
DE69708682D1 (de) 2002-01-10
WO1999007653A1 (fr) 1999-02-18
JP2001502290A (ja) 2001-02-20
CA2268019C (fr) 2007-03-13

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